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Engine Mechanical (KA24DE): Removal & Installation Nissan Frontier D22

Mechanical 15 illustrations ~694 words

Removal

CAUTIONAfter removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. Do not spill engine coolant on drive belts.

Scheme 52

Scheme 52: UPPER TIMING CHAIN
Scheme 52: UPPER TIMING CHAIN

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55
  1. Remove the air cleaner assembly.
  2. Remove the spark plug wires.
  3. Set No.1 piston at TDC on its compression stroke.
  4. Remove vacuum hoses, electrical harness connectors, and harness clamps.
  5. Remove the power steering belt.
  6. Remove the power steering pump and position it to one side. Remove the idler pulley and bracket as well.
  7. Remove the rocker cover. Loosen the bolts and remove in numerical order as shown.
  8. Remove the camshaft sprocket cover.
  9. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket.
  10. Remove cam sprocket bolts, cam sprockets and upper timing chain.
CAUTIONWhen installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket. Attach tags to valve lifters so as not to mix them up. Before removing camshaft and idler sprockets, apply paint marks to them for retiming.

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57
  1. Remove upper timing chain and idler sprocket. Refer to " «UPPER TIMING CHAIN»(ref-183499-S05185609282005081400000) " and " «IDLER SPROCKET»(ref-183499-S38464183472005081400000) " . For retiming during cylinder head removal/installation, apply paint marks to camshaft sprockets, upper timing chain, lower timing chain, and idler sprocket.
  2. Remove camshaft brackets and camshafts. Mark these parts' original positions for reassembly.
  3. Remove cylinder head bolts in numerical order. Removing bolts in incorrect order could result in a warped or cracked cylinder head. Loosen cylinder head bolts in two or three steps.
  4. Remove cylinder head and cylinder head gasket.

Scheme 58

Scheme 58: Installation
Scheme 58: Installation

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60
  1. Tighten cylinder head bolts in numerical order using the following procedure: Tighten all bolts to 29 N.m (3.0 kg-m, 22 ft-lb). Tighten all bolts to 79 N.m (8.1 kg-m, 59 ft-lb). Loosen all bolts completely. Tighten all bolts to 25 to 34 N.m (2.5 to 3.5 kg-m, 18 to 25 ft-lb). Turn all bolts 86 to 91 degrees clockwise. If angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then turn each cylinder head bolts 86 to 91 degrees clockwise.
  2. Install camshafts and camshaft brackets in the order shown using the following procedure: Set camshafts and camshaft brackets. Dowel pins of both intake and exhaust camshafts should be at 12 o'clock positions when installing the camshafts. Tighten all bolts to 2 N.m (0.2 kg-m, 17 in-lb). Tighten all bolts to 9.0 to 11.8 N.m (0.92 to 1.2 kg-m, 79.9 to 104.2 in-lb). Apply new engine oil to bolt threads and seat surfaces.
  3. Install upper timing chain and idler sprocket. Refer to " «UPPER TIMING CHAIN»(ref-183499-S15968694442005081400000) " and " «IDLER SPROCKET»(ref-183499-S04627584872005081400000) " .

Removal and Installation

SEC. 112

Scheme 61

Scheme 61: Removal and Installation
Scheme 61: Removal and Installation
WARNINGPosition vehicle on a flat and solid surface. Place chocks at front and back of rear wheels. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. Before disconnecting fuel hose, release fuel pressure. Refer to , "FUEL PRESSURE RELEASE ". Be sure to hoist engine and transmission in a safe manner. For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG.
CAUTIONWhen lifting engine, be sure to clear surrounding parts. Take special care near accelerator wire casing, brake lines and brake master cylinder. In hoisting the engine, always use engine slingers in a safe manner. Before separating engine and transmission, remove the crankshaft position sensor (OBD) from the assembly. Always take extra care not to damage edge of crankshaft position sensor (OBD) or ring gear teeth.

Scheme 62

Scheme 62: REMOVAL
Scheme 62: REMOVAL
  1. Drain coolant from engine block and radiator. Refer to CHANGING ENGINE COOLANT .
  2. Release fuel pressure. Refer to , "FUEL PRESSURE RELEASE ". Disconnect the fuel hose.
  3. Remove negative battery cable.
  4. Remove hood. Refer to "REMOVAL AND INSTALLATION ".
  5. Remove air cleaner.
  6. Remove power steering drive belt, generator drive belt and A/C compressor drive belt.
  7. Remove radiator. Refer to "RADIATOR ".
  8. Remove exhaust manifold heat shield.
  9. Disconnect exhaust system at rear of TWC (manifold).
  10. Remove A/C compressor from bracket. Refer to "COMPRESSOR MOUNTING ".
  11. Disconnect accelerator wire, vacuum hoses, electrical connectors, heater hoses and vacuum booster hose.
  12. Remove four power steering pump bolts.
  13. Remove transmission. Refer to (manual) "REMOVAL AND INSTALLATION ", or (automatic), "REMOVAL ".
  14. Install engine slingers and attach engine lift hooks.
  15. Remove LH and RH engine mounts.
  16. Lift and remove engine.

INSTALLATION

  1. Install in reverse order of removal.
CAUTIONWhen installing sliding parts (bearings, pistons, etc.), lubricate contacting surfaces with new engine oil. Place removed parts such as bearings and bearing caps in their proper order and direction. When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. Do not allow any magnetic materials to contact the ring gear teeth of flywheel or drive plate.

Scheme 63

Scheme 63: PISTON AND CRANKSHAFT
Scheme 63: PISTON AND CRANKSHAFT

Scheme 64

Scheme 64
Scheme 64
  1. Place engine on a work stand.
  2. Drain coolant and oil.
  3. Remove oil pan.
  4. Remove timing chain. Refer to " «REMOVAL»(ref-183499-S37049652612005081400000) " .
  5. Remove water pump.
  6. Remove cylinder head.
  7. Remove pistons with connecting rods.
  8. Remove bearing caps and crankshaft. Before removing bearing caps, measure crankshaft end play. Refer to " «CRANKSHAFT»(ref-183499-S27265482762005081400000) " . Bolts should be loosened in two or three steps.

Scheme 65

Scheme 65: PISTON AND PISTON PIN CLEARANCE
Scheme 65: PISTON AND PISTON PIN CLEARANCE
  1. Measure inner diameter of piston pin hole "dp". Standard diameter "dp": 20.993 - 21.005 mm (0.8265 - 0.8270 in)
  2. Measure outer diameter of piston pin "Dp". Standard diameter "Dp": 20.989 - 21.001 mm (0.8263 - 0.8268 in)
  3. Calculate piston pin clearance. dp - Dp = -0.002 - 0.01 mm (-0.0001 - 0.0004 in)

If it exceeds the above value, replace piston assembly with pin.

Scheme 66

Scheme 66
Scheme 66

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